SLCCC Best Practices Awards 2008 Journalism Institute Renovation

SLCCC - Best Practices 2008
Donald W. Reynolds Journalism Institute - Missouri School of Journalism

DONALD W. REYNOLDS
JOURNALISM INSTITUTE
University of Missouri - Columbia

St. Louis Council Construction Consumers
Award Submission
October 24, 2008

SLCCC BEST PRACTICES AWARDS 2008


ExECUTIVE SUMMARY
The new $19.0M Donald W. Reynolds School of Journalism at the University of Missouri
– Columbia involved three interconnected buildings including interior renovation of Walter
Williams Hall, a 1930’s era building, the complete renovation of the original 1890’s era
Sociology Building and the construction of a new, modern “Link” building. The Sociology
building included a new poured in-place concrete frame “building within a building”.

It was found that the 120 year-old Sociology building had crumbling masonry walls and
foundations. Many constructability issues were created due to the condition of the Sociology
building including interior and exterior temporary bracing and structural reinforcing of the
120 year-old building shell. The temporary bracing also created many conflicts with new
construction work. Other challenges included custom construction of new roof steel and
“drifting” steel frames thru the existing wooden roof structure.

Unique features of the “building within a building” concept included horizontal wind braces
from the old building shell to the new concrete frame and interior glass walls around the
perimeter of the new structure. Other project features included matching the original stained
glass windows, a structural glass walkway and a new TV studio.

Despite the severe unforeseen conditions jeopardizing the project’s survival, the Sircal/
Kozeny-Wagner team presented creative and responsible solutions to very challenging
engineering conditions that resulted in salvaging the project, not to mention one of the
landmark historical centerpiece buildings to the University of Missouri Columbia Campus.


INTRODUCTION

Sircal/Kozeny-Wagner a Joint Venture was selected, by competitive bidding, as the General
Contractor for the new $19.0M Donald W. Reynolds School of Journalism at the University of
Missouri – Columbia. (Photo 1.) The project involved three interconnected buildings including
interior renovation of Walter Williams Hall, (Photo 2.) a 1930’s era building, the complete
renovation of the original 1890’s era Sociology Building (Photo 3.) and the construction of a
new, modern “Link” building. The Sociology building included a new poured in-place concrete
frame “building within a building”. More details about the “building within a building” concept
will be provided below.

BEST PRACTICES

This Best Practices submission will focus mainly on the constructability practices and methods
used for the renovation of the 1890’s Sociology Building. (Photo 3.) However, many other Best
Practices were utilized including materials management, team building, quality management,
change management and zero accident techniques. Through the course of the project the
construction team field verified every critical dimension and devised ingenious methods to
overcome hidden conditions, design challenges and problematic existing conditions.

FOUNDATIONS
Initially the project team set out to investigate the depth and thickness of the existing
fieldstone foundation (Photo 4.) of the 120 year-old Sociology Building. Hand excavations
were made at various locations and it was found that the foundation varied in depth up to
4’ around the perimeter of the building. This required custom fabrication of all drilled pier
reinforcing cages (Photo 5.) and ‘haunch” beam steel. (Photo 6.) The drilled piers and haunch
beams were required to stabilize and reinforce the building foundation before additional work
could proceed. After installation of the drilled piers, the haunch beams were hand excavated
(Photo 7.) and custom formed for each location. (Photo 9.) The initial investigation and
attention to existing conditions allowed the drilled pier and haunch beam construction (Photo
8.) to proceed smoothly eliminating costly change orders and potential delays.

ROOF STEEL
During investigation of the foundations, the project team also acknowledged the importance
of existing dimensions for the fabrication of new roof support steel. (Photo 10.) The project
superintendent, project engineer and steel shop drawing detailer spent many days investigating
the existing roof structure and existing conditions while taking accurate dimensions for
fabrication of the new roof support steel. It was ultimately determined that each new steel
support must be custom fabricated due to the 120 year-old existing conditions.


It was also determined that even accurate existing dimensions and custom fabrication would
not insure proper fit of some steel members. Miscellaneous angles and structural tee (WT)
joist hanger sections (Photo 11.) were shipped loose and field welded in place as existing
conditions dictated.

STEEL ERECTION
The bid documents indicated that the existing roof was to remain in place and did not address
access for installation of new steel. The project team and the erection contractor developed
a plan to cut “slot” openings (Photo 12.) through the existing roof to “drift” the new steel into
place. (Photo 13.)

Intense preplanning for fabrication and erection of the new roof steel kept erection on
schedule and costly change orders due to a minimum. (Photos 14, 15, 16,17, 18.)

ExISTING MASONRY WALLS
In preparation to set the new roof steel, existing masonry bearing walls were uncovered and
inspected by the project team. It was found that many of the existing bricks were crumbling
and too weak to support the roof loads. It was also found that the original field-mixed mortar
had deteriorated and had virtually no strength. Bricks could be removed by hand from existing
structural walls. (Photo 19.) The 1890’s building structural integrity was unstable and put at
risk the project’s ultimate success. Due to the historical importance of the 1890’s structure,
Sircal/Kozeny-Wagner was challenged to develop solution to save the structure. Through
creative and responsible engineering solutions, the building was saved and project vision was
realized.

CUSTOM BUILDING BRACES
The project team engineered custom bracing to support the crumbling masonry building.
Custom bracing included 4x4 buck frames (Photo 20.) to hold windows square, interior bracing
to support walls and hold building corners square (Photos 21, 22, 23, 24,25.) and extensive
exterior bracing (Photo 26.) to carry wind and potential seismic loads while an engineered
“fix” was developed to save this historic 120 year-old building. (This temporary bracing would
remain in place for more than a year creating many more complications, while the “fix” was
completed and new structural elements were able to carry wind and seismic loads.)

MASONRY REINFORCING
A new project team member was added, Masonry Solutions International to engineer the
“fix” for the crumbling 120 year-old walls. The on-site project team facilitated the new design
by removing areas of existing brick for engineering investigations and performing in-place
strength tests of the existing walls and foundations (Photo 26a.).

Plans and specifications (Photos 27, 28, 29, 30.) were developed that required new horizontal
and “stitched” reinforcing for the existing exterior walls. “Stitched” reinforcing was added
to the walls by drilling holes at 30-degree angles, (Photo 31.) in two directions, through the


existing three and four wythe thick brick walls. The project team also experimented with
drills, drill bits, drill supports and drill braces (Photo 32.) to determine the most efficient
methods to drill more than 50,000 reinforcing holes through the crumbling brick walls and
foundations. (Photo 33.) As the holes were drilled and reinforcing bars installed, (Photos 34,
35.) a structural grout slurry mix (Photos 36, 36a.) was pumped into all wall cavities, through
the stone foundations and at all new reinforcing locations.

BASEMENT LEVEL CONSTRUCTION
After the building was structurally reinforced and certified by the engineer, the team
undercut the existing basement slab by approximately 8’ as part of the new “building within a
building” concept. (Photos 37, 38, 39, 40, 41.) A new poured in place 3-story concrete frame
would be constructed inside the old 2-story 1890’s building shell. Extreme care was taken
throughout construction to protect the temporary bracing (Photo 42, 43.) and to not disturb
the existing field stone foundations.

CONFLICTS WITH TEMPORARY BRACING

The temporary bracing was to remain in place (Photos 44,45,46.) until the new concrete
slabs and columns could carry the exterior wind loads and potential seismic loads. The existing
foundation bearing elevation would now be approximately 4’ above the new basement floor
slab. (Photos 47, 48.) Low headroom drill rigs (Photos 49, 50, 51.) were utilized to complete
the interior drilled piers while maintaining the temporary building braces in place.

The project team also devised a plan to maintain the exterior temporary bracing while the
new “Link” building floor slabs were constructed. (Photos 52, 53, 54.) With the help of the
structural engineer, exterior braces were located so that they would pass through the new
elevated slabs (Photos 55, 56.) in locations that would not compromise the integrity of the
new structure.

After completion of the new concrete “Link” structure the braces were removed and several
small deck pours were made to fill in the temporary openings in the new pan slabs. This
constructability technique allowed new construction to continue despite the interference of
the exterior temporary bracing supporting the Sociology building.

SEPARATION OF NEW & OLD STRUCTURAL LOADS
Several other aspects of the “building within a building” concept required close attention to
constructability. The floor slab elevations of the new three-story structure did not line up
with the floor slab locations of the old two-story building. (Photo 57.) The new three-story
structure was held approximately 2’ away from the old exterior walls. (Photo 58.) New floor
slab loads would be carried by the new concrete structure. Floor slab loads were not to be
imposed on the existing exterior Sociology walls even after installation of the structural
reinforcing designed by Masonry Solutions.


PERIMETER GLASS WALLS
The differing floor slab elevations required close attention to layout and dimensions for wind
bracing of the exterior walls and many other building components. The existing exterior
windows also did not line up with the new floor slab elevations. Glass walls were installed as
architectural “fall protection” due to the 2’ gap around the new floor slabs and the potential
hazard of existing window locations. (Photos 59, 60.) The perimeter glass walls also allowed
natural sunlight to fill the new classrooms and offices through the old exterior windows.

HISTORIC WINDOW REPLACEMENT
Close attention to constructability was also required to match the historic 1890 window
profiles (Photo 61.) and original stained glass window patterns. (Photo 62.) Multiple field
meetings were held along with many iterations of shop drawings for modern aluminum window
profiles to “match” the historic, hand-made window profiles. The team also searched for and
found the original stained glass manufacturing company to replace several stained glass
windows. (Photo 62.) The University and the Historical Society were very pleased with all the
new replacement windows, since the window profile and stained glass” match” were nearly
perfect.

DIFFERING FLOOR SLAB ELEVATIONS
Another constructability concern was the (10) different floor slab elevations in (3) separate
buildings, Walter Williams Hall, the Sociology building and the new “Link” building, that
comprise the new Journalism School. The three separate buildings connect to the adjacent
buildings thru various ramps and stairs. (Photos 63, 64, 65.) One of these ramps included an
opaque glass walkway (Photo 66.) with clear glass sidewalls below a glass skylight, creating a
dramatic architectural feature connecting the new “Link” building to the Sociology building.
(Photo 67.)

STRUCTURAL GLASS WALKWAY
The project scheduled required the structural glass walkway to be constructed first, with
framing and finishes completed later in the project. Protective measures and great care were
taken while installing metal stud framing, MEP rough-ins, painting, ceilings and decorative
wood panels above this walkway. Scores of workmen crossed this walkway every day, over
many months, during the construction of the J-School project. Only one damaged glass
panel was replaced due to extreme care and protection during the construction process.

“TYPICAL” CONSTRUCTABILITY ISSUES
The Journalism School entailed many other “typical” constructability issues including, limited
access for deliveries, limited lay down area, tower crane placement, utility trenches below
walkways (Photo 68.) and maintaining student access and sidewalks on the busy Mizzou
campus. (Photo 69.) To further challenge the project team, the Journalism School was also
constructed during the wettest period on record, winter/spring 2008.


CLOSING

Despite the severe unforeseen conditions jeopardizing the project’s survival, the Sircal/
Kozeny-Wagner team presented creative and responsible solutions to very challenging
engineering conditions that resulted in salvaging the project, not to mention one of the
landmark historical centerpiece buildings to the University of Missouri Columbia Campus.
Best Practices recommends that the constructor become involved early in the planning
process to recognize and solved constructability and many other issues prior to start of
construction. Although, this was not the case here.

We believe that this project demonstrates that a professional construction team adds
tremendous value no matter what stage they become involved in a complex addition/renovation
project. The new Donald W. Reynolds School of Journalism was successfully completed and
ready for the first day of class in August 2008. The Journalism School includes a new library
(Photos 70, 71.), computer labs (Photo 72.), a café (Photo 73.), an auditorium with raised
seating (Photo 74.), a TV studio (Photos 75, 76.), along with new facility offices and many
new classrooms. (Photos 77. & 78. show the exterior of the completed “Link” and Sociology
buildings).


Photo 1 Photo 2

Photo 3 Photo 4

Photo 5 Photo 6


Photo 7 Photo 8

Photo 9 Photo 10

Loose
Angles

Field Welded WT

Photo 11 Photo 12


Photo 13 Photo 14

Photo 15 Photo 16

Photo 17 Photo 18


Photo 19 Photo 20

Photo 21 Photo 22

Photo 23 Photo 24


Photo 25 Photo 26

Photo 26A Photo 27

Photo 28 Photo 29


Photo 30 Photo 31

Photo 32 Photo 33

Photo 34 Photo 35


Photo 36 Photo 36 A

Photo 37 Photo 38

Photo 39 Photo 40


Photo 41 Photo 42

Photo 43 Photo 44

Photo 45 Photo 46


Photo 47 Photo 48

Photo 49 Photo 50

Photo 51 Photo 52


Photo 53 Photo 54

Photo 55 Photo 56

Photo 57 Photo 58


Photo 59 Photo 60

Photo 61 Photo 62

Photo 63 Photo 64


Photo 65 Photo 66

Photo 67 Photo 68

Photo 69 Photo 70


Photo 71 Photo 72

Photo 73 Photo 74

Photo 75 Photo 76


Photo 77 Photo 78

SLCCC Best Practices Awards 2008 Journalism Institute Renovation

Empfohlen

Empfohlen

Weitere ähnliche Inhalte

Was ist angesagt?

Was ist angesagt? (20)

Andere mochten auch

Andere mochten auch (17)

Ähnlich wie SLCCC Best Practices Awards 2008 Journalism Institute Renovation

Ähnlich wie SLCCC Best Practices Awards 2008 Journalism Institute Renovation (20)

SLCCC Best Practices Awards 2008 Journalism Institute Renovation